Casting mold



March 12, 1935. F, M.-POE 1,993,801

CASTING MOLD Filed March 7, 1951 4 Sheets-Sheet 2 F. M. POE

CASTING MOLD March 12, 1935.

Filed March '7, 1931 4 Sheets-Sheet 3 March 12, 1935. POE 1,993,801

CASTING MOLD Filed March 7, 1931' 4 Sheets-Sheet 4 I Indentor:

Patented Mar. 12, 1935 stares sire OFFEE CASTING MOLD Application March '7, 1931, Serial No. 520,782.

11 Claims. (Cl. '22--126) This invention relates to casting molds of that class commonly referred to as repetition or permanent molds and which are intended for use in the manufacture of railway brake shoes and other castings which are produced in large quantities.

One of the objects is to provide a novel casting mold consisting of metal and refractory parts wherein the likelihood of breakage of the refractory parts is reduced to a minimum. r

Another object is to provide a casting mold comprising a cope and a drag having theengaging faces thereof disposed in intersecting planes to facilitate and insure registration of the cope on the drag.

A further object is to support the moldfor movement into diiferent positions to expedite the performance of the various operations in the use thereof.

, In the selected embodiment of my invention illustrated in the accompanying drawings,

Fig. 1 is a side elevational view of my improved mold;

Fig. 1a is a fragmentary sectional view on the line 1a1a of Fig. 3;

Fig. 2 is a plan View of the drag taken on the parting line as indicated by the line 2-2 on Fig. 1;

Fig. 3 is a sectional view taken substantially on the line 33 on Fig. 2; and

Fig. 4 is a plan View of the cope taken on the v parting line as indicated by the line 44 on Fig. 3.

In the accompanying drawings, 5 indicates a base of suitable character having upright brackets 6, 6 providing bearings 7, 7 in which trunnions 8, 8 fast on the drag 9 are journaled whereby the mold may be turned either into the vertical position illustrated in full lines in Fig. 1, or into the horizontal position shown in dotted lines in said figure. To retain the mold in either of these two positions a spring-pressed pin 10, .mounted in one of the brackets 6, is extendible into proper of suitably located openings, such as 11, in the adjacent side wall of the drag. The drag comprises a metal shell 12, which may be a suitably shaped casting, the bottom wall of which has openings 13 therein to reduce the weight. At intervals along the side and bottom Walls of the shell are ribs 14 having grooves 15 in the inwardly disposed faces thereof. A block 16 of refractory material is arranged in the shell in engagement with the inner faces of the ribs and in the faces of the block juxtaposed to the sides of the shell recesses 15 are formed which communicate with the grooves 15. A suitable material 16', such as soft metal, for example, lead or Babbitt metal, or a. plastic substance such carborundum or Portland cement, is introduced into the grooves 15 and the recesses communicating therewith and this material serves to interconnect the block 16and the shell 12. In the shell at opposite ends of the block 16 are metal chill blocks 17 and 18. These chill blocks engage the ends of the block 16 and are clamped thereagainst by adjusting bolts 19 and 20 mounted in the end Walls of the shell. By properly positioning the adjusting bolts prior to the introduction'of the material into the grooves 15, the longitudinal location in the shell of the chill blocks and the refractory block may be determined. The cope 21 comprises a metal shell-22, which may also be a suitably shaped casting, the upper wall of which has openings 23' therein to reduce the weight. At intervals along the side and top walls ofthe shell. ribs 23 are provided having grooves 24 in the inwardly disposed faces thereof. A block 25 of refractory material is arranged in this shell in engagement with the ribs and in the faces of the block, juxtaposed to the sides of the shell, recesses 24 are formed which communicate with the grooves 24 and a suitable material 25, such as that introduced into the grooves 15, is introduced into the grooves 24 to interconnect the block 25 and the shell 22. The material introduced into the grooves 15 and 24 not only flows along the sides of the refractory blocks in the cope and drag but also flows through grooves between the ribs at the backs of the cope and drag, and this material not only secures the refractory blocks to the shells by flowing into the recesses but likewise tends to elfect securing by-reascn of the surface contact with the refractory blocks. Further, this material in the grooves serves as a reenforcement. The mold cavity C is formed in the refractory blocks 16 and 25 and the chill blocks 17 and 18. The portions of the cavity in the chill blocks are of slightly less size than the portion thereof in the refractory block 16 and thus the edges of the chill blocks engaging the refractory block are disposed slightly inwardly of the adjacent edges of said refractory block and consequently the edges of the refractory block are eifectively protected against chipping,

this disposition of these edges being clearly illussage P. This core may be made of sand, like, or substantially like, hard sand cores customarily made in foundry practice and it is therefore porous and frangible. The mold cavity is curved longitudinally and therefore, if the parting, defined by the engaging faces of the cope and drag, be disposed in a horizontal plane it is possible that this parting might not intersect the cavity at certain portions thereof. I dispose engaging faces of the cope and drag in flat intersecting planes extending at an angularity somewhat similar to the curvature of the mold cavity. Even if the mold cavity were not curved longitudinally it would be advantageous to dispose these engaging faces in intersecting planes for by arranging the planes to intersect substantially medially of the longitudinal extent of the mold an apex is provided on the drag which will neatly interfit with a complementary recess on the cope to thereby facilitate and insure proper registration of the cope on the drag. By arranging the engaging faces of the cope and drag in fiat intersecting flat planes I am enabled to dispense with the curved surfaces formerly provided. It is easier to attain a neat fit between two abutting flat surfaces than between two curved surfaces, and this also insures a neater mold cavity. Moreover, by disposing these engaging faces in fiat intersecting planes I am enabled to provide flat surfaces on the faces of the chill blocks which greatly facilitates the machining thereof and this also insures better fitting of the chill blocks with the opposing surfaces on the refractory block of the cope. To further insure proper registration of the cope and drag, ears 34 are formed on the side walls of the shell 12 in which pins 35 are fast. On the side walls of the shell 22, ears 36 are formed having openings 37 therein and when the cope is disposed on the drag the pins 35 pass through the openings 37 to thereby align the cope and drag. 0n the side walls of the shell 22, shouldered studs 34 are formed on which hook clamps 38 are pivotally mounted. When the cope is arranged on the drag the hook clamps may be turned about the studs to engage the hook portions thereof with the sections of the trunnions 8 intermediate the side walls of the shell 12 and the bearings 7 and therefore the cope and drag are interconnected so that when the mold is pivoted on the trunnions 8 displacement of the cope from the drag is prevented. On the base 5 in spaced relation with the brackets 6 is a rest 39. On the end of the cope opposite the pouring gate, foot portions 40 are provided. When the cope is removed from the drag the foot portions 40 are disposed on the rest 39 to support the cope in vertical position to thereby afford access to all sides. The refractory block 25 has a centrally located recess 41 to receive the cores 43 and 44' which may be assembled as a unit with the lug strap 42 and the reenforcing back 44 as an insert B. The cores and lug strap are arranged in the recess 41 with the back 44 disposed in the cavity C. The back 44 is held snugly against the Wall of the mold cavity in the cope and the lug strap and cores are held in the recess 41 by a looped wire 45. A tapered opening 46 in the block 25 extends between the inner end of the recess 41 and the outer surface of the block with the greater diameter at the inner end thereof. This opening maybe of polygonal cross section to prevent turning of a similarly shaped spacer 47 mounted therein. The spacer 47 is narrower than the opening and thus passages 48 are defined at the sides thereof and the ends of the wire 45 are passed through these passages and about the back and are united to secure the back, lug and the cores in position. The bight of the looped wire passes over the grooved cam 49 fast on a shaft 50 journaled in a bracket 51 carried by the shell 22. The shaft 50 is operated by a unitary crank 52 which, when turned to increase the eccentricity of the cam, serves to tighten the wire 45 to thereby tightly clamp the back in position. The back 44, lug 42 and the cores therefor are arranged in the portion of the mold cavity in the block 25 of the cope when it is disposed on the rest 33 and therefore access to all sides thereof may be readily had. The disposition of the spacer 48 in the opening 46 protects the refractory when the crank 52 is operated for should too much tension be applied to the wire 45 in securing the parts in position there would be a tendency to crush the refractory. In addition to installing the back, lug and the cores therefor in the cope when it is disposed on the rest 39, the cores 53 are also installed, these cores being positioned prior to the installation of the back 44. As best illustrated in Fig. 3, opposite ends of the mold cavity in the block 25 are enlarged to provide end lugs on the shoe. The cores 53 are arranged at the inner ends of these enlarged portions and the inwardly disposed faces of the cores are tapered and cooperate with correspondingly tapered walls of the enlarged portions for a purpose to be set forth. After the cores 53, back 44, lug 42, and cores 43 and 44 have been installed and the wire 45 has been tightened the cope is ready to be positioned on the drag which at this time will be arranged in the dotted-line position of Fig. 1. Handles 54 are provided on the cope to facilitate movement thereof from the rest 39 onto the drag. After the cope has been arranged on the drag with the pins 35 extended through the openings 3'7 and the hook clamps 38 have been engaged with the trunnions 8, the spring-pressed pin 10 will be retracted from the opening 11 in which it has been disposed and the mold will be rotated into the vertical position illustrated in Fig. 1. The pin 10 will then be inserted in the other of the openings 11 and the mold will be retained in vertical position to receive molten metal which is poured thereinto through the pouring gate liner. During the cooling of the metal poured into the mold it will shrink from the ends toward the center. As this shrinking occurs the sprue remaining in the pouring gate liner will shrink with the shoe and be urged toward the center of the mold and this action will crush the pouring gate liner. Likewise, this shrinkage will crush the cores 53 and by reason of the tapered surface provided on these cores and the refractory block the stress attendant to this crushing will be so dissipated that there will be no tendency to break the refractory. Since the casting shrinks from its ends toward the center, the cores 43 and 44' may likewise be crushed. The liner 33 and the cores 43, 44 and 53 are frangible and will crush when the casting shrinks and thus prevent damage to the refractory blocks 16 and 25. It has been pointed out that the portions of the mold cavity in the chill blocks 17 and 18 are of smaller size than the portion thereof in the block 16 and therefore as the shrinking occurs there will be no tendency to crack the refractory for the edges thereof are disposed outwardly of the edges of the chill blocks and therefore the edges of the casting formed in the chill blocks may shrink past the edges of the refractory without damage thereto. The molten metal flowing in the mold cavity will contact with the spacer 4'7 and will be chilled and in this manner leakage through the passages 48 is prevented; A short time after themetal has been poured into the mold, the "pin 10 will be removed from the opening '11 from which it has been disposed and-the mold will be turned into the horizontal position shown in dotted lines in Fig. l, the pin 10 being disposed in the other of the openings 11 to retain the mold in this posi-.

tion. When the casting has cooled, the clamps 38 will be disconnected and the cope will be removed from the drag, the wire 45 being out prior to this removal. In the event the wire 45 should tend to stick in the passages 48, the spacer 47 may be knocked out of the copeand after the casting has been removed the spacer may be freed from the wire. After the cope has been removed from the drag the foot portions 40 thereof will be disposed on the rest 39 and a back, lug, and cores may be positioned therein in the manner previously described for the next molding operation.

While I have illustrated and described a selected embodiment of my invention, it is to be understood that this is capable of variation and modification and I therefore do not wish to be limited to the precise details setforth but desire to avail myself of such changes and alterations as fall within the purview of the following claims:

I claim:

1. A repetition casting mold comprising a drag having a mold cavity, chill blocks seated in the wall of the mold cavity and having portions of the mold cavity therein, refractory material seated in the wall of the mold cavity adjacent the chill blocks and having a portion of the mold cavity therein, the portions of the mold cavity in the chill blocks being smaller transversely than the portion of the mold cavity in the refractory material to permit longitudinal contraction of a casting while cooling in the mold cavity without damaging the edges of the refractory material.

adjacent the chill blocks.

2. A repetition casting mold comprising adrag having a mold cavity, chill blocks seated in the drag at the ends of the mold cavity and having the end portions of the mold cavity therein, and a refractory block seated in the drag between the chill blocks and having the middle portion of the mold cavity therein, the end portions of the mold cavity in the chill blocks. being smaller transversely than the portion of the mold cavity in the refractory block adjacent the chill blocks to permit longitudinal contraction of a casting while cooling in the mold cavity without damaging the edges of the refractory block adjacent the chill blocks.

3. A repetition casting mold comprising a drag having a mold cavity, chill blocks seated in the drag at the ends of the mold cavity and having the end portions of the mold cavity therein, and a refractory block seated in the drag between the chill blocks and having the middle portion of the mold cavity therein, the edges of the chill blocks engaging the refractory block being disposed slightly inwardly of the edges of the refractory block to permit longitudinal contraction of a casting while cooling in the mold cavity without damaging the edges of the refractory block. 7 V

4. A repetition casting mold having a mold cavity and comprising a cope, said cope including a shell and a refractory block seated in the shell and forming a wall of the mold cavity, said refractory block having a recess opening into the mold cavity, means mounted on the shell and holding an insert in place in the mold cavity for embedment in the casting, a part of said insert being located in said recess, a core between the part of theinsert in' the recess and the bottom of the recess, and non-frangible means intermediate the core and the shell to prevent the holding means from damaging that part of the refractory block intermediate the recess and the shell.

5. A cope for a'casting mold comprising a shell, a refractory block in the shell and having a part of a mold cavity formed in one face thereof, said block having a recess therein opening into the mold cavity,'said block having an opening therein extending from the recess to the face of the block opposite the mold cavity, a core in said recess, a spacer in the opening and extending between the core and the shell, retention means passed through said opening and said recess and adapted to hold in the mold cavity an insert for the casting to be made therein, and means for tightening said retention means to secure said insert in the mold cavity, said spacer protecting the refractory material against crushing by the force incident to the tightening of said retention means.

6. A cope for a casting mold comprising a shell, a refractory block in said shell and having a part of a mold cavity formed in one face thereof, said block having a recess therein opening into the mold cavity, said block having a polygonal open ing therein extending from said recess to the face of the block opposite the mold cavity, a core in said recess, a spacer shaped similarly to said opening and mounted therein and extended between the core and the shell, retention means, said core and said spacer having openings therein through which said retention means is extended to be engaged with an insert for the casting to be made in the mold cavity and means for tightening the retention means to secure the insert in the mold cavity, said spacer protecting the refractory material against crushing by the force incident to the tightening of said retention means.

7. A repetition casting mold having a mold cavity and comprising cope and drag members, one of said members comprising a metal shell having ribs spaced apart on the inner walls thereof, and a refractory block mounted in said shell and engaging said ribs whereby said block is spaced from the inner walls of the shell, said ribs being grooved between the side edges thereof, and a material in the grooves of said ribs interconnecting-the block and the shell to prevent displacement of the block from the shell in the operation of the mold.

8. A repetition casting mold having a mold cavity and comprising cope and drag members, one of said members comprising a metal shell having two side walls and a connecting wall, continuous ribs spaced apart and'extending transversely of the side walls and the connecting wall, and a refractory block mounted in said shell and engaging said ribs whereby said block is spaced from said walls of the shell, said ribs being grooved between .the side edges thereof, and a material in the grooves of said ribs interconnecting the block and the shell to prevent displacement of the block from the shell in the operation of the mold.

9. A drag for a casting mold comprising a metal shell, a refractory block mounted in said shell, chill blocks at the ends of said refractory block, and adjustable means for forcing said chill blocks into engagement with the ends of said refractory block to thereby clamp said blocks in said shell.

10. A drag for a casting mold comprising a metal shell having ribs on the inner walls thereof, a refractory block mounted in said shell and engaged with said ribs, chill blocks in said shell at opposite ends of said refractory block, adjustable means mounted at the ends of said shell and adapted to force said chill blocks into engagement with the ends of said refractory block to clamp said chill blocks in position, and means securing said refractory block in said shell.

11. A drag for a casting mold comprising a metal shell having ribs on the inner walls thereof, a refractory block mounted in said shell and engaged with said ribs, chill blocks in said shell at 10 opposite ends of said refractory block, adjustable means mounted at the ends of said shell and adapted to force said chill blocks into engagement with the ends of said refractory block to clamp said chill blocks in position, said ribs being arranged in pairs and having a groove between the ribs of each pair providing pockets, and a material introduced into said pockets for securing said refractory block in said shell.

FRED M. POE. 

